Oil burner safety control system, including a flame responsive thermocouple structure



April 8, 195? w. A. RAY A l. 2,592,068

01E BURNER sAEETY CONTROL sYsTEN, INCLUDING A FLAME RESPONSIVE TEERMocoUPLE STRUCTURE Original Filed Nov. 5, 1940 2 SHEETS- SHEET T Me/9.574776 (0A/7662 issus@ S xlll Aprll 8, 1952 w. A. RAY 2,592,068

OIL BURNER SAFETY CONTROL SYSTEM, INCLUDING l A FLAME RESPONSIVE THERMOCOUPLE STRUCTURE Original Filed Nov. 5, 1940 2 SHEETS-SHEET 2 UND QL U lT JUNCTION COLD JUNCTION WUWOJU SUN TIME.

Patented Apr. 8, 1952 OIL BURNERi SAFETY CONTROL SYSTEM,

INCLUDING A FLAME RESPONSIVE THER- MOCOUPLE STRUCTURE William A. Ray, North Hollywood, Calif., assignor to General Controls Co., a corporation of California Original application November 5, 1940, Serial No. 364,356, now Patent No. 2,466,274, dated April 5, 1949. Divided and this application July19, 1948, Serial No. 39,477

5 Claims.

This invention relates to a system for controlling the operation of a fuel burner, as may be utilized for furnaces. An example of a system of this general character whereby it is assured that the supply of fuel will be discontinued and the igniting means deenergized in the event the burner fails for any reason, is shown in Patent No. 2,113,858, issued on April 12, 1938, in the name of William A. Ray, and entitled Control Unit. l

This application is a division of a prior ap plication filed November 5, 1940, for Thermocouple Operated Control System, in the name clude a pair of conductors of dissimilar metals,

which are joined or fused together to form one or more hot junctions. When the temperature of the hot junctions suitably exceeds that of other junctions, between the conductors or in the thermocouple circuit, there is a generation of electrical energy in the circuit. All this is now well understood and no further explanation thereof is required.

l In the event of name failure (as of a main oil burner), it is essential that the thermocouple respond promptly to this condition, so that the fuel supply may be shut off and the system rendered inactive. By the aid of this invention, these effects are obtained, since the thermocouple junctions promptly assume substantially equal temperatures.

It is another object of this invention to simplify the thermocouple structure that may operate in this desired manner, when both the cold and hot junctions are subjected to the radiant heat of the flame and away from the liame. Appropriate temperature differential effects are obtained by properly positioning the conductors and junctions.

It has been suggested, as for example in the Patent No. 2,139,504, issued Dec. 6, 1938, to W. ,L King, that a thermocouple structure might be used in which generation of the thermoelectric current occurs as a transient phenomenon. Thus the thermoelectric current flows for a limited interval when it is rst subjected to the source of heat; and correspondingly, it flows for another limited interval upon making the source of heat inactive. These transient e'ects are intended to be utilized in the control apparatus described by King. While King also suggests a form of thermocouple mounting that is intended to maintain a constant temperature differentialbetween the hot and cold junctions during operation of the furnace, the temperature diiferential in that case is stated to be due to the use of special means for facilitating heat transfer from the cold junctions.

It is accordingly another object of this invention to ensure that the thermocouple structure operates steadily .to generate a current when the hot and cold junctions are exposed substantially equally to a source of heat, bythe use of simple means for effecting a temperature difference between said junctions.

This invention possesses many other advantages, and has other objects which may be made more easily apparent from a consideration of several embodiments of the invention. For this purpose there are shown several forms in the drawings accompanying and forming part of the present specification. These forms will now be described in detail, illustrating the general principles of the invention; but it is to be understood that this detailed description is not to be taken in a limiting sense, since the scope of this invention is defined by the appended claims.

Referring to the drawings:

Figure 1 is a diagrammatic representation of a system incorporating the invention;

Fig. 2 is an enlarged sectional view, of a thermocouple structure utilized in the system of Fig. 1;

Fig. 3 is a sectional view, similar to Fig. 2, but illustrating a form of the invention in which a series of pairs of thermocouple junctions is utilized, the section being taken along the plane 3--3 of Fig. 5;

Fig. 4 is an end view, as seen in the direction of the arrow, from the right hand of Fig. 3;

Fig. 5 is an end View of the structure illustrated in Fig. 3 taken from the left hand end thereof;

Fig. '6 is a diagram illustrating the I nanner in which the multiple pairs of junctions may be connected together in series; and

Fig. 7 is a `graph exemplifying the operation of the control system when utilizing the invention.

In the forms shown in Figs 1 and 2, the furnace wall I may serve to define a furnace space, in which fuel, for example oil in divided form', may be burned; however, other fuels, liquid, gaseous, or solid may be utilized. The supply of fuel into the furnace space is shown as provided by an oil burner structure 2 having a blower motor 3 therefor, and provided with vaporizing means. The burner flame 22 is shown as extending substantially horizontally, although in some instances it may take other positions. The ignition of the Vaporized fuel is shown as being accomplished by an electric spark or ignition device 4 adjacent the oil burner opening. This ignition device 4 is shown as being supplied with energizing current at the proper electromotive force, from the secondary winding of a suitable transformer 5.

In the operation of oil burners that are intended to be under the control of a thermostat, it is quite essential to ensure that the burner 2 and the blower motor 3 will be shut down in the event that the fuel fails to ignite; and also in the event that after ignition, the flame fails for any reason. In this Way, fuel waste is stopped and dangerous fire hazards are obviated. Furthermore, it is desired automatically to disconnect the igniting means 4 after the system is in full operation.

This general type of automatic control is known; one form thereof is illustrated in the prior patent to W.v A. Ray hereinbefore referred to. The automatic safety control devices needed for such a system are indicated diagrammatically by the rectangle 6. The electrical energy for operating the control system and the blower motor 3 may be -supplied from the mains 1.

to the heat of the burner flame and responds thereto. The heat of the burner flame causes the device 9 to become active; a relay II) is thereupon energized and its front contact I I is closed, whereby the automatic system B acts to disconnect the transformer 5 from its source of energy, thereby deenergizing the ignition device 4. In the position shown in Fig. 1, the relay I0 is unenergized, the back contact I2 being closed. This condition may exist at the start of the operation of the furnace. When the thermostatic control means 8 causes energization of the ignition device 4, the circuits completed by back contact I2 are such as temporarily to maintain the ignition circuit active. If after a short time the relay I0 is still unenergized, indicating a failure of the burner 2 to light, then the automatic safety control devices operate to shut down the system 4 cuit for the motor 3 and to maintain the ignition circuit deenergized. In the event of flame failure also, the same results are obtained, due" to the response of the device S to the lowered temperatures in the furnace chamber.

The thermal responsive device 9 is in the form of a thermocouple, and this thermocouple is of such character that it will generate a sufficient current to operate the relay I0 when the burner 2 is active. The structure of the thermocouple is shown to best advantage in Fig. 2.

The thermocouple device has a pair of junctions I3 and I4. These junctions are both subjected to the radiation from flame 22, as by being exposed within the furnace chamber. The thermocouple 9 may be placed as closely to the nozzle of burner 2 as desired, although this spacing is not critical, so long as the junctions are subj ected to the intense radiation of the flame. The conductors forming these junctions are of such character, as will be hereinafter described, as steadily to maintain the temperature of the junction I4 suitably above the temperature of the cold junction I3, in spite of the fact that both junctions are subjected to the radiant heat of the flame, and that the system is operating in a state of equilibrium. How this effect is secured will now be described.

The cold junction I3 is formed by the fusion oi a short conductor I5 to a terminal conductor I6. The hot junction I4 is formed by the fusion of the short conductor I5 with a conductor II. Conductor I5 is made from a metal or alloy dissimilar from the metal or alloy of which conductors IB and Il are made. Thus for example, conductor I5 may be made from ChromeL an alloy which can withstand quite high temperatures; and conductors I6 and Il may be made from Copel," which is also capable of withstanding high temperatures. In the arrangement illustrated, the junctions I3 and I4 are both exposed to the radiant heat of the flame temperatures; however, the temperature gradients (as may be determined, for example, by thermal conductivity of the conductors, or by the spatial relationship of the junctions to the name), are purposely made such that the temperature of the hot junction I4 remains suitably elevated above that of cold junction I3. Such an effect may be obtained even when the thermal conductivities of the conductors I5, I6 and I1 are substantially equal; such a form will be described hereinafter.

In the form shown in Fig. 2, the mass of conductor I6 subjected to furnace temperatures is purposely made greater than that of conductor Il; for example by an increase in sectional area. Also, the junctions I3 and I4 are placed preferably quite closely together so that they may be substantially' equally subjected to the heat of flame 22.

Due to the difference in mass of conductors I6 and Il, the furnace temperature adjacent the junction I3 is less than at junction I4 connected to the smaller mass Il. This is partly due to the more rapid withdrawal of heat from the surrounding heated gases through the mass I6 tc the exterior of the chamber. The effect is enhanced by the normal greater temperature of the furnace chamber at the junction I4 which is purposely placed farther within the furnace chamber.

The intermediate Chromel conductor I5 is also of small sectional area, such as conductor I1, so as to retard transfer of heat by conduction from junction I4.

The choice of Copel for the end conductors yo-f junction I4.

n leads I8 and I9, connecting the thermocouple 9 to the relay I in any appropriate manner. The coil of relay I0 thus completes the thermocouple circuit. The connection between conductors I6 and I8, and the connection between conductors I1 and I9 have no appreciable effect upon the operation of the thermocouple, since the thermoelectric junctions thus formed produce substantially equal but opposing electromotive forces.

A practical embodiment of the invention may be made in which conductors I5 and I1 are of No. 18 gauge wire; and conductor I6 is of No. 12 gauge wire. The lead-in wires I8 and I9 may be of No. 14 gauge copper wire. The element I5 between the junctions may have a length of the order of 1% inch.

One manner in which the thermocouple structure may be supported by the wall l is indicated in Fig. 2. Thus a tube lining may be provided for an aperture through the wall I. Through this aperture the conductors I6 and I1 extend. These conductors may be supported in spaced relation in the tube 20, as by the aid of a refractory plug 2 I, through which the conductors I6 and I1 pass. This plug structure 2| may be appropriately supported, as by an adherent, in the interior of the tube 20. The space in lining 20 that is not'occupied by the conductors I6 and I1 and block 2I is in communication with the furnace chamber and the heated gases therein.

The mode of operation of the system may now be summarized. For this purpose reference may be had to Fig. 7. Assuming that the furnace is started from a cold condition, and that thermostat 8 operates to permit the automatic systemy to go'into action, the burner 2 and ignition means 4 are operated. As soon as the flame 22 ignites, the temperature of junction I4 rises steeply until a constant temperature is attained. This may take a matter of seconds. The temperature of junction I3 meanwhile rises more slowly. During this transient period, a suicient temperature difference is obtained to energize relay I0; and front contact II of relay I0 is active. The ignition means 4 is deenergized. The junction I3 assumes an equilibrium temperature below that While this temperature difference is not as great as required to operate relay I0, yet .it is ample to ensure against dropping out of the relay.

Afterv the furnace is in operation for a while, the thermostat 8 may return to a position in which the burner 2 should be rendered inactive; or there may be a flame failure. Under such circurnstances the safety devices are operated to ductors I5. I6 and I1 causes a prompt equilization of the junction temperatures by an equalizing flow. This point is illustrated by the con- 6 junction of the hot and cold junctions temperature graphs at the right hand portion of Fig. '7. I'he hot junction rapidly loses heat, the cold junction more slowly. The heated walls of the furnace do not interfere with this equalization "as" the heat effect of the walls is not comparable with that of the flame 22, Which is the prejdminating factor in transmitting heat to the th'ermocoup1e structure.

By employing a. sufliciently sensitive relay I0, a single pair of thermocouple junctions I3 and I4 is sufcient to close the relay at the beginning `f ame operation and to maintain the relay closed until the flame 22 fails or is otherwise extinguished. It has been found that Yas muchv 'as six or seven millivolts may be produced by the `@thermocouple structure during equilibrium conditions. When the resistance of the complete `flo'ad circuit is of the order of 0.060 ohm, the power -Ltlius produced is 0.6 milliwatt. It has been found that when the flame 22 is extinguished, the jY-'vltage across the terminals of relay I0 -drops in f a few seconds to releasing value, as illustrated by tlie point in the diagram of Fig. 7 labeled: relay opens."

However, in some instances it may be desirable to multiply the thermoelectric current, asv

'lby using a plurality of thermocouples in ser-ies. Such an arrangement is illustrated in Figs. 3 to 6 inclusive.

Thus, instead of having a single pair of ther- -rmocouple junctions, there are three such pairs.

:l-Each of the pairs has a cold junction 23 and a ihot junction 24, made substantially identically `with the construction illustrated in Fig. 2. The

jf two of the conductors 21 may be joined. as by 'welding or fusing, to points 28 upon two of the vlarge conductors 26. The third of the large con- Vd'uc'tors 26, and the third of the small conductors `-2`I act as the terminals of the thermocouple n"'structure. To these terminal conductors, may be fused the copper conductors 29 and 30. k

The mode of operation of the multiple thermo- 'couple structure is substantially identical with .'-that described in connection with Fig. 2. All of the thermocouple junctions 23 and 24 are substantially uniformly 'exposed to the heat of the flame 22.

This flame 22 is the predominant factor in transferring heat to the thermocouple 00.l junctions.

Due to the fact that the conductors 26 reduce the temperature of the heated gases `to a greater extent than the conductors 21, and

can conduct heat at an increased rate, as com- `j,pared with conductors 21, the temperature of -junctions 23 are steadily maintained suitably below the temperatures of the corresponding junctions 24. The electromotive forces produced :'-ff at the hot junction are additive by the series connections illustrated in Fig. 6.

I claim: 1. `In a furnace system: wall means defining "fila `furnace chamber; a burner communicating Vwith said chamber; means for supplying fuel to .fisaid burner for burning as a flame; and means 'for controlling said fuel 'supplying means, including a thermocouple structure comprising a pair of conductors extending through said chamber wall and into said furnace chamber; means carried by said furnace chamber wall for mounting said conductors so that the inner ends of said conductors project only slightly into said chamber and lie closely adjacent said wall and to each other such that said inner ends will be substantially equidistant from said burner name, and the other ends of said conductors project exteriorly of said wall; said burner being arranged to direct the fuel so as normally not to reach said inner ends; a metal element joining the said inner ends of said conductors, said metal element forming with said joining inner ends a pair of junctions and said metal element being thermoelectrically dissimilar from the conductors which it respectively joins, said conductors each being of substantially the same material and length, but one of said conductors having a greater cross sectional area than the other of said conductors, such that heat is dissipated dissimilar-ly from said conductors to said mounting means, said chamber wall, and the exterior of said chamber forming means, in order to maintain one of said junctions at a lower temperature than the other of said junctions.

2. In a furnace system: wall means defining a furnace chamber; a burner communicating with said chamber; means for supplying fuel to said burner for burning as a flame; and means for controlling said fuel supplying means, including a thermocouple structure comprising a pair of conductors extending through said chamber wall and into said furnace chamber; means carried by said furnace chamber wall for mounting said conductors so that the inner ends of said conductors project only slightly into said chamber and lie closely adjacent said wall and to each other such that said inner ends will be substantially equidistant from said burner flame, and the other ends of said conductors project exteriorly of said Wall; said burner being arranged to direct the fuel so as normally not to reach said inner ends; a metal element joining the said inner ends of said conductors, said metal element forming with said joining inner ends a pair of junctions and said metal element being thermoelectrically dissimilar from the conductors which it respectively joins; a pair of connections respectively joined to the exterior ends of said conductors, said connections being less thermoelectrically dissimilar with respect to said conductors than is said metal element, said conductors each being of substantially the same material and length, but one of said conductors having a greater cross sectional area than the other of said conductors, such that heat is dissipated dissimilarly from said conductors to said mounting means, said chamber wall, and the exterior of said chamber forming means, in order to maintain one of said junctions at a lower temperature than the other of said junctions.

3. In a furnace system: wall means defining a furnace chamber; a burner communicating with said chamber; means for supplying fuel to said burner for burning as a flame; and means for controlling said fuel supplying means, including a thermocouple structure comprising a pair of conductors extending through said chamber wall and into said furnace chamber; means carried by said furnace chamber Wall for mounting 'ber and lie closely adjacent said wall and to each other such that said inner ends will be substantially equidistant from said burner flame, and the other ends of said conductors project exteriorly of said Wall; said burner being arranged to direct the fuel so as normally not to reach said inner ends; a metal element joining the said inner ends of said conductors, said metal element forming with said joining inner ends a pair of junctions and said metal element being thermoelectrically dissimilar from the conductors which it respectively joins; a pair of connections respectively joined to the exterior ends of said conductors, said connections being less thermoelectrically dissimilar with respect to said conductors than is said metal element, said conductors each being of substantially the same material and length, but one of said conductors having a mass greater than the other of said conductors, such that heat is dissipated dissimilarly from said conductors to said mounting means, said chamber wall, and the exterior of said chamber vforming means, in order to maintain one of said junctions at a lower temperature than the other of said junctions.

4. In a furnace system: wall means defining a furnace chamber; a burner communicating with vsaid chamber; means for supplying fuel to said burner for burning as a flame; and means for controlling said fuel supplying means, including a thermocouple structure comprising a plurality of pairs of conductors extending through said chamber wall and into said furnace chamber; means carried by said furnace chamber wall for mounting said conductors so that the inner ends of said conductors project only slightly into s'aid chamber and lie closely adjacent said wall and to each other such that said inner ends will be substantially equidistant from said burner name, and the other ends of said conductors projecting exteriorly of said wall; said burner being arranged to direct the fuel so as normally not to reach said inner ends, a plurality of metal elements joining the said inner ends of the pairs of conductors respectively, said metal elements forming with said joining inner ends a series oi pairs of junctions, and said metal element being thermoelectrically dissimilar from the conductors which they respectively join, said conductors being joined at the exterior ends so that, to-

gether kwith said metal elements, said conductors are in series relationship, and a pair of connections respectively joined to the end conductors in the said series arrangement exterior of said chamber forming means, said connections being less thermoelectrically dissimilar with respect to said conductors than are said metal elements, said conductors all being of similar material, but alternate conductors in said series relation having a greater cross sectional area than the other alternate conductors, such that heat is dissipated dissimilarly from alternate conductors to said mounting means, said chamber wall, and the exterior of said chamber forming means, in order to maintain one of the junctions in each of said pairs of junctions at a lower temperature than the other of the junctions in each of said pairs of junctions.

5. In a furnace system: wall means defining a furnace chamber; a burner communicating with said chamber having an opening for the passage of fuel; means for supplying fuel to said burner for burning as a name; and means for controlling said fuel supplying means including a thermocouple structure comprising a pair of conductors of substantially similar material extending through said chamber wall and into said furnace chamber; means carried by said Wall for mounting said conductors so that the inner ends of said conductors project only slightly into said chamber and lie closely adjacent said wall and to each other such that the inner ends will be substantially equidistant from said burner name, and the other ends of said conductors projecting exteriorly of said chamber forming means, said burner being arranged to direct the fuel so as normally not to reach said inner ends; a metal element joining the said inner ends of said conductors, said metal element forming with said joining inner ends a pair of junctions and said metal element being thermoelectrically dissimilar from the conductors which it respectively joins, and a pair of connections respectively joined to the exterior ends of said conductors,

' said connections being less thermoelectrically dissimilar with respect to said conductors than is said metal element.

WILLIAM A, RAY.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS 10 Number Name Date 2,113,858 Ray Apr. 12, 1938 2,139,504 King Dec. 6, 1938 2,156,235 Betz et ral. Apr. 25, 1939 2,193,516 Laing Mar. 12, 1940 2,304,489 Wetzel Dec. 8 1942 2,466,274 Ray Apr. 5, 1949 FOREIGN PATENTS Number Country Date 351,712 Great Britain July 2, 1931 

